Soap pad



' Feb. 18, 1964 M. L. JOHNSON 3,121,250

SOAP PAD Filed Au 10, 1961 1NVNTOR. MYRON L. JOHNSON BY G 5 ATTORNEY W Uited States Patent Ofiice 3,i2i,25 Patented Feb. 18, 1364 3,121,250 59A? PAD lii'yron L. .iohnson, Sipringiield, Ghio, assignor to International riteei Wool Corporation, Springfield, Ghio, a corporation of Ghio Fiied Aug. 10, 196i, Ser. No. 130,673 5 flaims. (1. -561) My invention which is disclosed and claimed in this application relates to pads for cleaning and scouring.

So-called soap pads (metallic wool pads impregnated with soap, detergent, and/or other cleaning agents) are now the most widely used means of cleaning and securing pots and pans. Such pads as presently manufactured, however, have certain drawbacks. They rust rapidly despite the use of various rust resistors or rust-arrestors. They retain the impregnated soap for a short time only, partly because the spaces between the individual fibers are large enough to permit water readily to reach and dissolve the soap, and partly because of the obviously non-absorbent nature of metal fibers. They are not recommended by manufacturers of stainless steel for use on utensils made of that material. In fact, some makers go so far as to warn against using regular steel wool on all stainless steel surfaces.

It is proper to say therefore that an ideal soap pad would need to possess exactly opposite characteristics. They should not rust. They should retain soap for longer periods. They should be made of a material acceptable to or recommended by makers of stainless steel products. On the first and third counts, the easy substitution of stainless steel wool or other rust-free metallic wool, or of a rust-free non metallic abrasive would fully meet the ideal specifications. This simple change, however, would not contribute anything as far as the second desirable attribute is concerned (i.e. the retention of soap for longer periods) and incidentally would result in a very high cost product especially when taking into consideration its relatively short life. To put the difficulties in another way, the prior art so-called soap pads have a short useful life at best, because they retain soap for only a brief period of active use. The water in which they are used quickly dissolves the soap and when this protective coating is removed from the steel fibers, a fast destructive and unpleasant rusting of the then unprotected steel wool results.

Various efforts have been made to slow down the rate of soap removal (e.g. Fisher, 2,621,355), or alternatively, to reduce the rate of rusting by using rust inhibitors, but these steps have increased the useful life of such pads by by very small amounts only. These experiences, in which the efforts have not been very successful, reflect the basic weakness of the past efforts to use metallic fibers such as steel wool, for two dissimilar purposes: (1) as an abrasive, for which they are well suited, and (2) as an absorbing medium, for which they are in no way suited, inasmuch as such fibers have no absorbent qualities to speak of. The non-absorbent nature of the metal fibers allows water to reach and dissolve the soap readily and then to rust the fibers.

The basic weaknesses of soap pads referred to above have thus resulted from the efforts referred to above to use metallic fibers for both (1) their natural function as an abrasive, and (2) an unnatural function as an absorbing medium. Attempts have therefore been made to produce a soap pad in which the scouring is done by metallic fibers, and the soap is held in a cloth pocket, a very thin web of non-metallic fibers, or an offset envelope formed of an absorbent material such as a natural or synthetic sponge-like material. These efforts also have not been very successful in the commercial field. This is probably due to the fact that in one case the cloth pocket is not intimately associated with the abrasive material and the soap or detergent is easily washed away without performing efiiciently its purpose in combination with the abrasive. Moreover, such a combination is complicated, expensive to manufacture and diilicult for the consumer to use especially in View of his unfamiliarity with the product. In the second case the thin web of non-meallic fibers is insufficient to contain a suific-ient or eficient quantity of detergent so that there is very slight, if any, improvement over the prior art metallic soap pads and in fact it seems doubtful whether the designers had clearly in mind the advantages of using separate materials for the separate functions (1) and (2) referred to above. Finally, the third type of pads have the same disadvantages as mentioned in connection with the first type, and therefore have not solved the problem.

I have found that a cleansing pad consisting of a relatively thick flexible detergent containing layer of predominantly naturally high water absorbing non-metallic fibers, to at least one face of which is secured a relatively thin abrasive layer (wherein the thickness of the detergent containing layer is at least three times the thickness of the abrasive layer and wherein the high water absorbing non-metallic fibers have a water absorbing factor of more than 5% at 65% relative humidity) solves the problems involved and produces a soap pad which retains soap for longer periods, rusts slowly, if at all, and will not be objectionable for use on stainless steel surfaces. If I go further and make the abrasive portion of the pad of stainless steel or of some other non-rusting metal, or some non rusting non-metal abrasive, I produce a soap pad which is useful for long periods of tirne, will not rust, is entirely acceptable to the manufacturers of stainless steel products and other stainless metal products, retains soap for long pen'ods of time and is generally much superior to all of the present day pads and those which have been heretofore suggested.

An object of my present invention therefore is a production of a soap pad which (a) does not rust rapidly, which (b) retains soap for a relatively long period of time and therefore has a relatively long useful life and which (0) is accept-able to manufacturers for the cleaning of stainless steel and other rust-free utensils.

' A further object of the invention is the provision of a soap pad having a relatively thick flexible detergent-containing layer of predominantly naturally high water absorbing non-metallic fibers to at least one face of which is secured a relatively thin abrasive layer.

A further object of my invention in one specific embodiment is the provision of such a cleaning pad in which the abrasive layer consists of rust resistant metallic fibers.

A further object of my invention in one specific embodiment is the provision of such a pad in which the abrasive layer consists of short particles of rust-resistant metallic fibers cemented or otherwise secured to the detergent containing layer.

A further more specific object of my invention is the provision of a soap pad using steel wool in which the destructive and unpleasant rusting of the steel wool is minimized.

A further object of my invention is the production of a scouring pad with increased soap retention qualities resulting from the use of a core or body of non-metallic natural or synthetic fibers or of natural or synthetic sponge.

A further object of my invention is the provision of a scouring pad with a core or body of naturally absorbent fibers or sponge to one or more surfaces of which a non-rusting abrasive material is attached by Whatever means.

A further object of my invention is to improve the character as well as the means and mode of manufacture and operation of fibrous cleaning pads impregnated with specially prepared soap or detergent material whereby the cleaning pad may not only be economically manufactured, but be more efficient in use, of increased durability and have a longer period of usefulness.

A feature of my invention is the selection of nonmetallic fibers which have a water absorbing factor of more than at 65% relative humidity and which preferably have a water absorbing factor of more than at 65% relative humidity.

A further feature of my invention is the provision of a cleaning pad in which there is a flexible detergent containing layer of non-'netallic fibers to which there is secured a relatively thin abrasive layer and in which the thickness of the detergent layer is at least three times the thickness of the abrasive layer.

In certain embodiments of my invention 1 secure a relatively thin abrasive layer to each side of a relatively thick detergent containing layer. In another embodiment of my invention I secure an abrasive layer to only one side of my relatively thick detergent containing layer with a suitable sealing compound such as rubber latex or plastic or flexible plastic provided to seal the opposite side.

Further features and objects of my invention will be apparent from the following specification and claims when considered in connection with the accompanying drawings illustrating certain embodiments of my invention.

In the drawings:

FIG. 1 is a view in perspective of a soap pad constructed according to my invention;

FIG. 2 is a view in elevation of the pad of FIG. 1;

FIG. 3 is an enlarged view in vertical section of the pad of FIGS. 1 and 2 having the central portion thereof broken away;

FIG. 4 is a view in section similar to FIG. 3 and showing an alternative embodiment of my invention;

FIG. 5 is a view in plan of the pad illustrated in FIG. 4; and

FIG. 6 is a view in elevation similar to FIG. 2, but showing another embodiment of my invention.

Referring now to FIGS. 1, 2 and 3, it may be seen that I have shown a soap pad 11 having an abrasive surface 12 and a relatively thick flexible detergent containing layer of predominantly naturally high water absorbing non-metallic fibers 13.

The relatively thick flexible detergent containing layer 13 of predominantly naturally high water absorbing nonmetallic fibers is as shown more than three times as thick as the thin abrasive layer 32 secured thereto. The detergent contain ng layer can be of any suitable nonmetallic natural or synthetic fibers with at least 50% of such fibers possessing high absorbent qualities for water, or any natural or synthetic sponge having the same qualities in which at 70* F. and 65% relative humidity 5.5% or more of water is absorbed and at 70 F. and 95% relative humidity 13.0% or more is absorbed and at 100 relative humidity the factor of water imbibition (sometimes called Q water imbibition) is 2G or higher. Q water imbibition is the quotient obtained when the bone dry weight of fiber is subtracted from the weight of the wet fiber after the latter has been centrifuged for five minutes at 1%90 gs. land the resulting difference is then divide-cl by 100 times the bone dry weight. Thus, the Q water imbibition is a measure of water absorbency at 100% relative humidity when equilibrium is approached from the wet side and Q equals the weight of centrifuged fiber minus bone dry weight divi ed by the bone dry weight multiplied by 100.

I prefer to use cotton felt for the layer 13. This cotton felt is impregnated with a detergent and then by use of an adhesive the abrasive layer 12 is secured thereto. Instead of cotton felt I can use any fabric, flannel, felt or sponge-like material possessing either or both of the following characteristics: (a) natural absorbing qualities as in cotton; (b) smaller and less accessible spaces than are possible with the grades of steel wool used in soap pads today between the individual fibers. Either characteristic reduces the rate at which the impregnating material can be Washed out and lost.

Non-metallic fibers possessing the characteristics above referred to include azlon (merinova), wool, rayon-cross linked, rayon-viscose, rayon cupramrnonium, linen (flax), rayon-polynosic, silk, rayon fortisan, cotton and acetate. The soap retaining body may be flannel, woven or knitted cloth, non-woven cloth, felt, pile fabric, batting, or any form of natural or synthetic fibers which have the water retaining characteristics referred to above. The diameter of the non-metallic fibers should be less than one-half the diameter of the metallic fibers used in the abrasive portion of the pad.

The abrasive layer 12 may be of any abrasive material metallic or non-metallic, but preferably consists of short particles of stainless steel wool fibers which are bonded to the detergent containing layer, as for example, by cement. It should have a thickness appreciably less than the thickness of the detergent containing layer. For example, if the detergent containing layer has a thickness of /s" the abrasive layer may be of the order of ,4 to 3&2 in thickness. Instead of stainless steel, I could use other rust resistant metal or alloy, as for example, Monel or a non-metal abrasive. Instead of short metal wool fibers, I could use long metal wool fibers, powdered metal, metal wire, sprayed metal fibers, metal shavings, or metal grits in any fineness, shape or arrangement.

Such non-metal non-rusting abrasives may include aluminum oxide, silicon carbide, garnet, emery, sand, flint, quartzite, pumice, diamond powder, tripoli, or plastic chips, grits, or powders. However, I prefer to use short particles of metal wood fibers of stainless steel having a diameter at least twice the diameter of the non-metallic fibers used in the detergent containing portion of the device. I prefer to add to the core of non-metallic fibers one or more surfaces of short metal wool fibers, long metal wool fiber-s, powdered metals, metal wire, sprayed metal fibers, metal shavings, metal grits, mesh shavings or particles. These are applied by any suitable means, such as by heat, adhesives, pressure, felting needles or by wrapping fibers around the core, and/or other means to attach the abrasive material, but I prefer the short metal fibers be secured to the detergent containing fibers by a cement. The abrasive could be metal wool, ferrous or non-ferrous, conventional fibers, or comminuted sprayed metal fibers, metal wires, mineral or glass fibers, mineral or synthetic grits, or a non-metal abrasive.

The non-metallic fibers of the core are saturated with detergent in the broad sense which includes as used in this application and claims not only detergents in the narrow sense, but also similar materials such as soaps and other cleaning or polishing agents, etc. I prefer to use soap in the detergent containing layer.

In the embodiment shown in FIGURES 4 and 5 there is provided a relatively thick non-metallic detergent containing layer 14, a relatively thin abrasive layer 15 and a sealing skin 16.

In the embodiment shown in FIG. 6, there is provided a relatively thick non-metallic deter-gent containing layer 17 and secured thereto on opposite sides thereof as by cement are a pair of relatively thin abrasive layers 18 and 19.

In each of the embodiment shown in FIGS. 4, 5 and 6, the detergent containing layer is at least three times the thickness of each of the abrasive layers and the fibers of non-metallic detergent containing layer have a water absorbing factor of more than 5% at 65% relative humidity. In each of these embodiments the detergent containing layer is approximately /8 and the abrasive layer or each of the abrasive layers is approximatel fl thick.

In the embodiment shown in FIGS. 4 and 5, the sealing component could, if preferred, be applied only to the face opposite the abrasive or preferably applied to the opposite side plus all four edges. The sealing component could be latex or any pliable plastic or elastomer applied as for example by spraying or dipping. Or it could be in the form of an impervious fabric attached to the pad by adhesives, staples or heat (with or Without pressure). This arrangement permits the water to reach the soap and the soap to work out of the pad through one face of the pad only. As a result, the length of time during which soap is retained is increased by a considerable amount.

It is to be understood that the above described embodiments of my invention are for the purpose of illustration only and various changes may be made thereto without departing from the spirit and scope of the invention.

1 claim:

1. A cleaning pad consisting of (l) a relatively thick flexible detergent containing layer of predominantly naturally high Water absorbing non-metallic fibers consisting of a sheet of cotton felt having a thickness of approximate-1y and impregnated with detergent, in which the non-metallic fibers thereof have a water absorbing factor of more than 5% at 65% relative humidity; (2) a relatively thin abrasive layer having a thickness of approximately secured to one face of the cotton felt layer and consisting of relat vely short particles of stainless steel wool fibers cemented to the detergent containing layer, in which the diameter of the individual steel wool fiber partimes is at least twice the diameter of the individual nonmetallic fibers of the detergent containing layer; and (3) an impervious flexible covering sealing the face of the cotton felt sheet opposite to the abrasive layer and sealing the four edges, the covering being of a thickness no greater than the thickness of the abrasive layer.

2. A cleaning pad consisting of a fiat relatively thick flexible detergent containing layer of cotton felt, impregnated with detergent, having cotton fibers, having a water absorbing factor of more than 5% at 65% relative humidity, having a Water absorbing factor of more than at 95% relative humidity, having a Q-water imbibition factor of more than 20 at 100% relative humidity, and having a thickness of approximately inch;

a relatively thin fiat abrasive layer, having a thickness of approximately A inch and composed of relatively short lengths of metallic wool fibers having diameters at least twice the diameter of the cotton fibers of the detergent containing layer; and

means comprising cement for bonding the abrasive layer to one face of the detergent containing layer.

3. A cleaning pad consisting of a fiat relatively thick flexible detergent containing layer of cotton felt, impregnated with detergent, having cotton fibers, having a water absorbing factor of more than 5% at relative humidity, having a water absorbing factor of more than 10% at relative humidity, having a Q-water imbibition factor of more than 20 at relative humidity, and having a thickness of approximately inch;

a relative thin flat abrasive layer, having a thickness of approximately inch and composed of relatively short lengths of metallic wool fibers having diameters at least twice the diameter of the cotton fibers of the deter-gent containing layer;

means comprising cement for bonding the abrasive layer to one face of the detergent containing layer; and

means comp-rising a relatively thin substantially water impervious flexible and pliable plastic covering cemented and secured to the face of the detergent containing layer opposite to that to which the thin abrasive layer is secured and also to the four edges of the detergent containing layer for substantially sealing the detergent containing layer against Water except through the abrasive layer.

4. The structure of claim 2 in which the short lengths of metallic wool fibers are short particles of stainless steel.

5. The structure of claim 3 in which the short lengths of metallic wool fibers are short particles of stainless steel.

References Cited in the file of this patent UNITED STATES PATENTS 1,551,192 Peiler Aug. 25, 1925 1,649,894 Field Nov. 22, 1927 1,978,169 Ricketts Oct. 23, 1934 2,308,405 Tully Jan. 12, 1943 2,885,703 Elliott May 12, 1959 2,889,568 Winch June 9, 1959 1. 039,125 Benjamin June 19, 1962 

2. A CLEANING PAD CONSISTING OF A FLAT RELATIVELY THICK FLEXIBLE DETERGENT CONTAINING LAYER OF COTTON FELT, IMPREGNATED WITH DETERGENT, HAVING COTTON FIBERS, HAVING A WATER ABSORBING FACTOR OF MORE THAN 5% AT 65% RELATIVE HUMIDITY, HAVING A WATER ABSORBING FACTOR OF MORE THATN 10% AT 95% RELATIVE HUMIDITY, HAVING A Q-WATER IMBIBITION FACTOR OF MORE THAN 20 AT 100% RELATIVE HUMIDITY, AND HAVING A THICKNESS OF APPROXIMATELY 3/8 INCH; A RELATIVELY THIN FLAT ABRASIVE LAYER, HAVING A THICKNESS OF APPROXIMATELY 1/16 INCH AND COMPOSED OF RELATIVELY 